JPH0749131B2 - Manufacturing method of honeycomb structure - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a honeycomb structure, in which a core and a shell of the honeycomb structure are integrally bonded to form a honeycomb structure. It is intended to improve the strength of the body.

[Prior Art and Problems Thereof] Honeycomb structures have been used in many applications such as aircraft and automobile parts because they are lightweight and have high strength.

This conventional honeycomb structure has a structure as shown in FIG. 11, and a core (1) having a so-called close-packed hexagonal lattice structure in which hexagonal cylinders are densely arranged, and the core (1) is attached to both sides of this core. It consists of shells (2) and (2). In some cases, the shells (2) and (2) are provided with side shells (20) so as to surround the core (1).

In this conventional one, the core is usually composed of a core material (10) made of an aluminum foil or a thin plate made of aluminum, and the core materials are partially bonded to each other in a strip shape in the thickness direction of the product. Then, this band-shaped adhesive area is laminated so that it is staggered between the joint core materials, and this is developed,
Hexagonal openings are closely arranged in a zigzag pattern on the end face. Then, the shells (2) and (2) are attached and fixed to the end surface of the core (1) by an adhesive so as to entirely close the open end.

In the case of this honeycomb structure, the core material (10) constituting the core (1) bears the strength against the load in the plate thickness direction in the figure. Even when a bending stress is applied, the hexagonal cylinders are densely continuous between the shells (2) and (2) facing each other at a constant interval, and sufficient strength is exhibited.

However, in the case of this conventional honeycomb structure, when the shell (2) is formed of a curved surface, the strength becomes insufficient, and the manufacture of this type of honeycomb structure is troublesome. It was

A shell (2) that is formed by molding the open end of the core (1) into a preset curved surface and then bending the core (1) to match the curved shape.
Since it is necessary to bond (2), it is difficult to exactly match the curved surface of the end surface of the core (1) with the inner surface of the shell (2), and the end surface of the core (1) and the shell (2) are This is because a defective adhesion portion is apt to occur.

In addition, the so-called side shell (20) provided so as to surround the peripheral portions of the shells (2) (2) of the honeycomb structure is cumbersome to bond, and actually, the upper and lower surfaces of the core (1) and A honeycomb structure of the type that is wholly surrounded, including its surroundings, is very expensive.

The present invention has been made in view of the above points, and in at least one of "a manufacturing method of a honeycomb structure in which an opening end surface and a peripheral side of a core (1) are integrally covered with shells (2) and (2)" It is an object of the present invention to improve the strength of the honeycomb structure including the case where the shell (2) on the surface is formed into a curved surface. Another object is to improve productivity by previously finishing the core (1) and one shell (2) in an integrally connected state.

* Regarding the invention of claim 1 [Technical means] The technical means of the present invention taken to solve the above-mentioned problem is "a core (1) extended and projected from one shell (2) and surrounding it. A step of integrally forming the side shell (20) by extrusion forging, a step of processing the constituent surface of the open side end surface of the core (1) and the end edge of the side shell (20) into a flat surface, and this flat surface It is composed of the step of joining and integrating the other shell (2) over the entire area ”.

[Operation] The above technical means of the present invention operates as follows.

At least one of the shells (2) is configured to include a side shell (20), and the core (1) formed therein is integrally coupled with the shell (2) and the side shell (20). It is formed by extrusion forging in the state of being formed. Therefore, no defective joint is produced between the core (1) and the shell (2) and the side shell (20) unlike the conventional one.

Further, since the shell (2) and the side shell (20) and the core (1) are integrally formed by extrusion forging, the shell (2) and the side shell (2)
Even if (0) is a curved surface, the core (1)
Is integrally extended to the inner surface of the curved surface. In addition, the open end of the core (1) is flat. Therefore, like the conventional honeycomb structure, the open end surface of the core (1) is less likely to cause defective bonding when the other shell (2) is covered by adhesion or the like and integrally bonded. Will be things.

[Effects] The present invention having the above-described configuration has the following unique effects.

Since the shell (2) and the side shell (20) and the core (1) are integrally connected, it is possible to prevent a decrease in strength due to a defective joint between the shell (2) and the core (1).

Even if the shell (2) and the side shell (20) are curved surfaces, the core (1) is molded integrally with them, so that the shell (2) and the side shell (20) are curved surfaces. The productivity of the structure is improved.

Furthermore, since the thickness distribution of the shell (2) and the thickness variation of each core material (10) can be set according to the strength distribution of each part of the product, the strength balance of the product can be optimized.

Also, the side shell (20) and the core (1) are the shell (2).
Since it can be integrally molded with the core (1), the through-hole peripheral walls penetrating the front and back can be integrated with the core (1), and the strength is improved in this respect as well.

* About the invention of claim 2 This invention achieves the same purpose as the invention of claim 1 described above, and the shell (2) on at least both sides of the core (1).
(2) can be formed on a curved surface.

The technical means for this is to "extend and integrate the core (1) by forging by extruding the core (1) on the inner periphery of the shell (2) that is equipped with a side shell (20) on the peripheral side and is entirely formed into a curved surface. Forming a pair of halves (a) and (b) and setting the planar shapes of the edges of the side shells (20) of the halves (a) and (b) to be the same. a)
It comprises a step of processing the open end of (b) into a flat surface and a step of joining and integrating the open end surfaces of the half bodies (a) and (b).

According to this means, the same effect as that of the invention of claim 1 is exhibited, and the productivity of the honeycomb structure having the curved surfaces on both sides of the core (1) is improved.

[Embodiment] An embodiment of the present invention will be described below with reference to FIGS. 1 to 10.

In the honeycomb structure of the embodiment shown in FIGS. 1 to 3, as shown in FIG. 3, both sides of the core (1) are shells (2) formed by integrally extending side shells (20), A honeycomb structure is formed by joining and integrating the shells (2) and (2) at their plane portions (11) and (11), and the shell has a curved surface on both sides of the core (1). (2) It becomes (2).

This honeycomb structure has a half body (a) as shown in FIG.
Although it is composed of (b), in this embodiment, it is formed in a mutually symmetrical shape.

In each of the halves, the main body portion of the shell (2) and the side shell (20) are continuously and integrally formed, and at the same time, at a position corresponding to a portion which becomes a through hole (22) penetrating to the front and back in a completed state. Are provided with tubular portions (21) and (21), and these tubular portions (21) are also formed integrally with the shell (2). Then, the side shell (20) and the tubular body portion (21)
In a space surrounded by (21), a core (1) in which hexagonal cylindrical portions are densely continuous is formed, and a core material (10) (10) serving as a ridge forming the core (1). Are formed at right angles to the flat surface (11).

Then, the flat portions (11) and (11) are joined and integrated by adhesion or welding (brazing). In this case, the end face of the cylindrical body part (21) and the end edges of the core materials (10) and (10) are also joined and integrated. Therefore, the cores (1) and (1) of the half bodies (a) and (b) are integrally connected to each other to form the half body (a).
It is built in the enclosed space surrounded by the shell (2) having the side shell (20) of (b), and moreover, coincides with the constituent wall surface.

Each of the halves (a) and (b) is manufactured by hot extrusion forging, but aluminum is used for this processing, and a forging die having a structure shown in FIGS. 4 to 7 is used. To do.

The forging die includes a male die (P) and a female die (D),
The female mold (D) is formed with a recessed portion (3) that matches the outer shape of the shell (2) including the side shell (20),
On the other male die (P), extrusion molding grooves (4) and (4) corresponding to the core materials (10) and (10) are formed in a continuous manner.

A pair of pins (31) and (31) that match the inner diameter of the through hole (22) project from the bottom of the recess (3).

On the other male mold (P), recesses (41) (41) matching the outer shape of the through hole (22) are formed at positions facing the pins (31) (31).
Are formed. In addition, the male die (P) is equipped with valve type extruding pins (40) (40), and the base end portion of the male die (P) can be raised and lowered in the empty chamber (42) formed in the male die (P). It is connected to a movable plate (43) housed in. still,
The push-out pins (40) (40) are urged together with the movable plate (43) in the descending direction at predetermined timing by the knock-out shaft portion (44).

Further, the details of the groove (4) and the push-out pin (40) are as shown in FIGS. 6 and 7, and the interval between the inlets of the groove (4) matches the wall thickness of the core material (10). The inside is set to be wider than the inlet. And in this embodiment, the gap between the inlets is set to about 0.5 mm,
The internal spacing is set to about 1.1 times this.

In addition, the tip of the push-out pin (40) has a conical valve part (45).
Is formed so that the lower end surface of the valve portion (45) is a flat surface that matches the lower end surface of the male die (P), and the insertion hole portion of the push pin (40) on the male die (P) side is formed. A valve seat portion (46) is formed on the end surface of the valve seat (46), and the conical surface of the valve portion (45) comes into close contact with the valve seat portion (46) during forging. And
The size of the valve portion (45) is set to a size close to the inscribed circle of the hexagonal tubular portion that constitutes the core (1).

When the halves (a) and (b) are manufactured using the above molds, the processing materials are Si: 0.4 to 0.8%, Mg: 0.5 to 1.2%, Fe:
Using a billet of aluminum less than 0.5% cut to 2 Kg, rough forging is performed once under the conditions of material temperature of 480 degrees and mold temperature of 300 degrees. This rough forging is a forging for forming a plate-like body whose volume distribution matches the wall thickness distribution suitable for the final finished shape, and is a pre-process of the final extrusion forging.

At the time of final finish forging, the rough forging material (S) is formed into a final shape by using a die including the male die (P) and the female die (D) described above. Incidentally, FIG. 4 does not express the wall thickness distribution of this rough forged material (S).

At the time of this final molding, the mold temperature and the material temperature affect the molding performance, but according to experiments, it is desirable to match the mold temperature with the recrystallization temperature of the material. For example, in the case of aluminum having the above-mentioned components, when the mold temperature and the temperature of the rough forging material (S) are maintained at 480 degrees and processed, the half body (a) of FIG. ) Or half (b) could be produced. The manufacturing dimensions of the half body (a) or the half body (b) are 100 mm in width, 500 mm in length and 25 mm in depth.

For reference, the heating temperature of the rough forging material (S) made of aluminum with the above components is 480 degrees, and the mold temperature is 200 degrees ~
The change in the pressing force required for processing when changing in the range of 400 degrees is as shown in FIG.

The actual processing of the rough forged material (S) under the above temperature conditions will be described.

As shown in FIG. 4, the rough forging material (S) is preliminarily formed with through holes (S ₁ ) (S ₁ ) matched with the pins (31) (31). It is housed in the concave portion (3) of the female mold (D) so as to be fitted to the pins (31) (31), and in this state, the male mold (P) is pressurized with a predetermined pressure. Then, the push-out pins (40) (40) in the protruding state come into contact with the rough forged material (S), the valve portions (45) (45) are pressed against the valve seat portion, and the push-out pin (40) slides. The airtightness of the section is secured. That is, in the male mold (P), the recessed part (41), the groove (4), the recessed part (3) and the male mold (P) are sealed except for the gaps. Then, when the pressure is further applied, the material of the rough forging material (S) is extruded and forged to a size regulated by the entrance of the groove (4) to form the core material (10) (10) as shown in FIG. At the same time, the through hole (22) and the side shell (20) are formed. And
The thickness of the shell (2) is male (P) to female (D)
By setting the stroke, the finished product will have a predetermined size.

Next, when the male mold (P) returns to its original position, the push pin (4
0) and (40) project downward by the advancing force of the shaft portion (44), and the half body (a) or half body (b) as a product is taken out from the male mold (P). At this time, since the end surface of the valve portion (45) at the tip of the push-out pin (40) is finished to a surface that matches the flat surface or the curved surface of the inner surface of the shell (2), the size of this end surface is the core material. (10) Since the size is close to the hexagonal plane surrounded by (10), even if the core material (10) (10) has a thin wall thickness as described above, Since the male material (P) is smoothly pulled out from the groove portions (4) (4), the core materials (10) (10) are not damaged when the product is knocked out.

At the time of completion of this forging, the surface of the flat surface portion (11) is not necessarily an accurate flat surface, but if it is cut or ground in a post process and finished to a flat surface, the half body (a) or half as shown in FIG. The body (b) is completed. In this example, half (a)
Since (b) has the same shape, a large number of half bodies (a) are manufactured and a pair of flat portions (11) are joined together to complete a product as shown in FIG.

In the case of the above embodiment, the flat portions (11) and (11) are directly joined to each other. However, as shown in FIG. 8, a plate material having a shape corresponding to the contour of the half body (a) is formed in the middle. Via (5),
The flat portions (11) of the pair of halves (a) and (a) may be joined to each other via this.

Further, as shown in FIG. 9, it is possible to manufacture a product from one half body (a) and the plate material (5).

Further, although the above-mentioned embodiment is manufactured by hot extrusion forging, it may be manufactured by cold extrusion forging.

[Brief description of drawings]

FIG. 1 is a plan view of a half body (a) or a half body (b) of an embodiment of the present invention, FIG. 2 is a sectional view thereof, and FIG. 3 is a sectional view of a honeycomb structure as a product, FIG. Is an explanatory view of the structure of a hot extrusion forging die, FIG. 5 is an explanatory view at the time of forging, FIG. 6 is an explanatory view of a main part at the time of forging, FIG. 7 is its plan view, and FIGS. 8 and 9 are FIG. 10 is an explanatory view of another embodiment, FIG. 10 is a relationship diagram between mold temperature and forging pressure, and FIG. 11 is an explanatory view of a conventional example, in which (1) ... core (2) (2) ……… Shell (20) …… Side shell (a) (b) …… Half body

Claims (2)

[Claims] 1. A method for manufacturing a honeycomb structure in which an open end surface and a peripheral side of a core (1) are integrally covered with shells (2) and (2), and a core (2) is extended and projected from one shell (2). 1) and a step of integrally forming the side shell (20) surrounding the same by extrusion forging, and the open side end surface of the core (1) and the side shell (20)
A method for manufacturing a honeycomb structure, comprising: a step of processing a surface constituting the edge of the plate into a flat surface; and a step of joining and integrating the other shell (2) over the entire flat surface. 2. A method for manufacturing a honeycomb structure in which an open end surface and a peripheral side of a core (1) are integrally covered with shells (2) and (2), and a side shell (20) is provided on the periphery and the whole is curved. The core (1) is extruded and forged to form a pair of halves (a) and (b) which are extended and integrated with each other on the inner surface of the shell (2) formed on the side wall of the halves (a) and (b). (20) The step of setting the same planar shape formed by the edges, the step of processing the open ends of the halves (a) and (b) into a plane, and the opening of the halves (a) and (b) A method for manufacturing a honeycomb structure, which comprises a step of joining and integrating end faces with each other.